Two Compartment Plastic Containers and Food Product Pack Comprising Such Containers

ABSTRACT

The container ( 1 ) for a dairy product or similar food composition is provided with a hollow body ( 2 ), a bottom ( 2   a ) and an opening ( 6 ) typically surrounded by a generally planar annular flange ( 7 ) connected to the top of the body. Two flexible closure lids ( 15, 20 ) are used to define with the side wall of the body an upper compartment that extends between the two lids. The lower compartment is filled with the food composition. The inner lid ( 15 ) has an annular outer portion which is in continuous annular contact with an inner shoulder of the side wall ( 4 ) and extends upwardly from a central covering portion. A spoon ( 18 ) or other solid content may be provided in the upper compartment, below the outer lid ( 20 ). Several identical containers ( 1 ) can be grouped in a pack with breakable junctions at an outer side edge of the flange.

FIELD OF THE INVENTION

The present invention generally relates to containers used in food packaging industry, particularly to thermoformed plastic flanged containers, such as yoghurt pots or similar. The invention also concerns a pack comprising such flanged containers and a method of combining a solid content and a food composition in a plastic container.

More particularly, the invention relates to a two compartment container for a food composition, in particular a dairy product composition, comprising:

-   -   a thermoplastic hollow body comprising a bottom, for example a         planar bottom, and a side wall extending along a longitudinal         axis from said bottom to a top,     -   a first flexible closure lid, for instance a foil, for         partitioning the interior volume of the body, so that a lower         compartment can be filled with a food composition, preferably a         liquid, semi-liquid, spoonable and/or scoopable food composition         and an upper compartment can contain a solid content, preferably         a solid food or object, and     -   a second flexible closure lid to seal the upper opening of the         body.

BACKGROUND OF THE INVENTION

DE 299 12 988 U1 discloses such a ready-to-eat food product. The body of the container comprises a flange that receives two superposed foils, one of which defines an inner cover member for partitioning the interior volume. A spoon may be stored without contamination with the food composition. This two foil configuration does not interfere with the structure of the side wall so that a conventional stacking of the containers is permitted. The side wall of the body may also be covered by a decorative strip or band (also called banderol). More generally, it is important as far as possible to reduce the unit cost of each packaging but without impairing its strength and its aesthetic characteristics.

It is known to produce such a container, and in particular a yoghurt pot or similar, by means thermoforming a sheet of plastic to form the volume. Typically, the plastic sheet is heated and then drawn into a cavity such as by vacuum and/or pressure. As the sheet is drawn into the cavity, the thickness of the portion of the sheet drawn into the cavity is reduced as the sheet material is stretched into the cavity. With such a method, the side wall of the body is thin, while the flange has the same thickness and the same rigidity as the original sheet of plastic. As the flange is thin and planar, the body essentially defines the height of the container.

Regarding the forming of the body, the thickness of the sheet material can be reduced when increasing the depth of the cavity. It can be appreciated that problems may occur where the plastic material rapidly changes angles in the volume such as at the bottom and sidewall of a cup-shaped container. It is thus not recommended having a too thin side wall for the purpose of sustaining the rigors of distribution.

The plastic containers shown in DE 299 12 988 U1 can be manufactured and sold as individual pots. The sealing operation using the two foils is typically performed with an individual thermoplastic body that is already thermoformed (no additional cutting operation is needed for the body). The individual containers are grouped in a stack before the sealing operation with storage of the spoon between two foils that are attached to each other. Such a two foil configuration is not adapted for manufacturing the plastic containers in a multiple portion packaging tray comprising an array of separable containers. In this latter case, after separation, each container flange still has four outer side edges so as to keep integrity of the content. Additionally these containers are typically made of relatively brittle plastic, which makes the containers more difficult to break apart. Such a difficulty may cause escape of the content when breaking other parts of the container. There is a need for solutions that have easier manufacture and/or handling.

The technology FFS (“form-fill-seal”) is typically used to produce at high rate conventional containers grouped in packs and each sealed conventionally by a single flexible closure lid (membrane). The machines using FFS technology are known as reliable to produce packs of such containers at high rate. More generally, it is understood that the containers are typically produced in very large quantities.

In food packaging industry, the plastic containers can be stacked on top of one another so as to form stacks which can be layered on a pallet. Using packs of several containers is highly preferred to optimise the loading of a pallet. A loading weight on a pallet may be much more than 500 kg. Such stacks allow the packaging items at the bottom to withstand the compressive load of the packaging items on top. The plastic containers layers are typically stored in cardboard trays each having a bottom and side walls preventing lateral tilting of the layers.

Additionally, the containers have to be easy to handle. When opening the plastic containers shown in DE 299 12 988 U1, the user often encounters difficulties to correctly peel off the respective foils. Accordingly, there is a need for providing ready-to-eat food products that are more user-friendly and well adapted to be produced by the most efficient industrial processes, for example adapted to multipack and/or FFS productions.

SUMMARY OF THE INVENTION

The purpose of the present invention is to provide attractive two compartment containers for a nomadic use while at the same time having a comparable or higher mechanical properties and addressing one or more of the above mentioned problems.

To this end, embodiments of the present invention provide a two compartment container for a food composition, comprising:

-   a thermoplastic hollow body comprising a bottom and a side wall     extending along a longitudinal axis from the bottom to a top; -   a first annular surface formed on an interior face of the side wall,     the first annular surface extending between the bottom and the top     of the hollow body; -   a generally planar second annular surface surrounding an upper     opening of the container; -   a first flexible closure lid, sealed on the first annular surface; -   a second flexible closure lid, sealed on the second annular surface     so that an upper compartment is defined at the opposite from the     bottom between the first flexible closure lid and the second     flexible closure lid;

wherein the side wall is provided with an inner shoulder that defines a slope and wherein the first flexible closure lid comprises:

-   a central covering portion that defines an upper limit of the lower     compartment; -   an annular rim; and -   an annular outer portion that comprises the annular rim and extends     upwardly from the central covering portion to the annular rim, said     annular outer portion being in continuous annular contact with the     inner shoulder.

With such an arrangement of the first flexible closure lid, removal of the second flexible closure lid can be easily performed by the user (and possibly without any interference with the removal of the first closure lid). A better sealing of the lower compartment is obtained as accidental removal of the first flexible closure lid is prevented.

The fact that the shoulder defines a slope is advantageous to allow stacking of individual containers and strength of the side wall remains high so that the thickness/amount of plastic material may be reduced. Such containers can be produced for highly competitive markets, using processes that reduce the unit cost of each packaging, but without impairing the strength of the container that is easy-to-handle.

Preferably, the upper portion of the side wall is connected to the lower portion of the side wall via the inner shoulder which is rounded to define a curved connection profile between the lower portion and the upper portion. Such a connection profile is adapted for a large coverage by a decorative strip. The curvature which is preferably continuous makes also the stacking of individual bodies easier. As no sharp edge or relief is provided, contamination inside a hollow body is prevented. Indeed, risks of contamination are typically higher in pronounced angles of a surface.

Such a solution may be used with various shapes for the body. For instance, the body may be provided with a planar bottom or may be a generally spherical body. Additionally, it is understood that the annular shape of the first annular surface may be rounded, oval, square-like, substantially rectangular, with symmetry around a central axis or without any symmetry.

In various embodiments of the container of the invention, recourse may optionally also be had to one or more of the following dispositions:

-   -   the side wall is annularly covered by a decorative strip having         a maximum height equal or superior to the height of the lower         portion or a decorative strip having a rectilinear upper edge         adjacent to the curved connection profile (the strength of the         side wall may be increased by using such decorative strip and         the thickness of the side wall may be optionally reduced in the         covered area);     -   the side wall is provided with more than one radius of curvature         above the lower portion and below the top of the hollow body and         the lower portion may have a conical shape at least at a         distance from the bottom (with such a shape, the annular outer         portion of the second closure lid may be attached to an annular         surface of the side wall that is radially shifted outwards with         respect to the lower portion and radially shifted inwards with         respect to the top of the body, whereby catching the annular         outer portion or a tab protruding therefrom is facilitated);     -   the inner shoulder has a constant height which is superior or         equal to 2 mm (such height being thus significantly higher than         the thickness of the thin film-material of the first closure         lid);     -   the first flexible closure lid is a one-piece foil of a film         material and the annular outer portion is folded with respect to         the central portion; the second flexible closure lid is also a         one-piece foil of a film material (the film material, having a         thickness typically inferior to 100 μm, is easy to cut and         pre-cut, and well adapted for use in high rate industrial         processes);     -   the annular rim of the first flexible closure lid is axially         spaced from the top of the hollow body (such configuration is         suitable to reduce the amount of material used in the first         closure lid and accidental opening of the first flexible closure         lid is efficiently prevented);     -   the first flexible closure lid comprises a flap, preferably a         pull tab, adapted for removing the first flexible closure lid         from the first annular surface, the flap protruding radially         outwards and/or inwards in a folded state, the flap comprising a         free end that extends at a distance from the inner shoulder         (with such a configuration, easy catching of the flap is         obtained);     -   the container comprises a generally planar annular flange         integral with the body and connected to the top of the body, the         flange defining the second annular surface and comprising an         inner edge that defines the upper opening of the container, the         annular rim of the first flexible closure lid being preferably         shifted radially inwards with respect to the inner edge (with         such an arrangement, accidental pasting of the second closure         lid to the annular rim of the first closure lid is prevented);     -   the body has a flanged cup-like shape and is stretched from a         plastic sheet, preferably with a stretching ratio comprised         between 2 and 7, preferably between 2.5 and 3.5 (such ratio         being defined in a known manner between the final surface of the         body and the corresponding initial planar surface);     -   the body of the container defines a cavity partly filled with a         dairy product; in particular the dairy product may be a yoghurt         composition having a weight not inferior to 50 g and not         superior to 500 g;     -   the flange defines a circular opening and comprises at least         three outer straight side edges, the outer straight side edges         optionally comprising two parallel outer straight side edges and         at least one outer straight side edge perpendicular to the two         parallel outer straight side edges, and wherein when four of         said first flange portions are provided on the flange, four         corresponding outer straight side edges are provided and define         a virtual square;     -   the flange has a constant thickness which is higher than the         thickness of the sidewall at the inner shoulder;     -   the lower compartment is filled with a food composition,         preferably a dairy product, and the upper compartment contains         an article in a solid state that is preferably adapted for         scooping the food composition;     -   at least one of the second flexible closure lid and an upper         portion of the side wall optionally comprises a transparent         material or a semi-transparent material so that the upper         compartment can be viewed before removal of the second flexible         closure lid.

A further purpose of the invention is to provide a food pack easy to be manipulated in a supermarket (before exposure of the containers by the operators and thereafter by the final consumer) and resistant while reducing amount of plastic material.

To this end, embodiments of the present invention provide, in a food pack, a plurality of containers according to the invention arranged in at least one row, and preferably at least four containers arranged in two rows, the flanges of the pack being integrally formed and separably joined to each other at a breakable junction between two flange portions of two distinct containers of the pack.

Accordingly, there is provided a pack produced at a reduced cost, which is particularly well adapted for transportation in a stackable tray, and including two compartment containers.

It is also provided, according to the invention, a method of making the two-compartment container, the method comprising:

-   -   filling the cavity defined by the hollow body with a food         composition below an inner shoulder of the container;     -   shaping a first flexible closure lid according to a 3D shape         when attaching an annular outer portion of the first flexible         closure lid to the inner shoulder, in order to seal a lower         compartment of the container, the annular outer portion         extending upwardly and continuously contacting the inner         shoulder;     -   positioning through the upper opening a solid content into an         upper compartment of the container above the flexible closure         lid;     -   closing the upper opening and sealing the upper compartment by         attaching a second flexible closure lid to the top of the body.

The empty container used for such process (starting recipient that can be filled with food composition) is provided with an upper opening and comprises the thermoplastic hollow body which defines a cavity of the container. The upper end of the container (which defines the upper opening) is preferably flanged.

Other features and advantages of the invention will become apparent to those skilled in the art during the description which will follow, given by way of a non-limiting example, with reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal section view of a two compartment container according to an embodiment of the invention;

FIG. 2 is a side view of a two compartment container similar to the container of FIG. 1;

FIG. 3 is a perspective view of the container of FIG. 1;

FIGS. 4A and 4B show a same detail of a container of FIG. 3 respectively with and without the membrane seal that defines the first closure lid;

FIG. 5 is a close-up view of the embodiment shown in FIG. 3;

FIG. 6 illustrates a stack of thermoplastic hollow bodies which can be used in a method of producing two compartment containers according to a first embodiment of the invention;

FIG. 7 is a top view of the container of FIG. 1 after removal of the second closure lid;

FIG. 8 shows a top view of an individual thermoplastic hollow body before filling with the food composition;

FIG. 9 schematically illustrates some steps of a method of producing two compartment containers according to a second embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

In the various figures, the same references are used to designate identical or similar elements.

FIGS. 1-3 show a two compartment container 1 that comprises a hollow body 2 and a sealing system 3. The hollow body 2 comprises a bottom 2 a and a side wall 4 extending along a longitudinal axis X from the bottom 2 a to a top 5. The bottom 2 a is generally planar or has as shape adapted for maintaining the container 1 in a more or less vertical position. The side wall 4 comprises an upper portion 4 a and a lower portion 4 a. Here in a preferred option, this lower portion slightly tapers toward the bottom 2 a. The height h1 of the lower portion 4 b is more than half of the height H of the container 1. With such an arrangement, the lower portion 4 b is particularly useful for displaying information and is typically covered by a rectangular shaped strip St arranged in a form of a sleeve label. In a similar embodiment the body 2 is partially covered by a sticker.

It can be seen in FIGS. 1-2 that the upper portion 4 a has a larger cross-section, so as to increase the size of the upper opening 6 that defines the single access to the interior volume V of the container 1. The longitudinal axis X may be a central axis, preferably a symmetry axis, for the side wall 4 and the opening 6. The sealing system 3 extends above the lower compartment C1 and comprises two barrier layers B1, B2, one of which is used to close the upper opening 6. The other barrier layer B1, which is air tight, is used to define an upper limit of the lower compartment C1 which is filled with a food composition 60. For instance, the food composition 60 is a dairy product.

More generally, the lower compartment C1 of the containers 1 is intended to be filled with food compositions, preferably a liquid, semi-liquid, spoonable and/or scoopable food composition, for example cakes, a liquid or semi-liquid dairy product or similar food (compote, sauce, desserts for instance), preferably a yoghurt composition. The containers 1 can be used for 50-500 g capacity, preferably 75-200 g capacity. Of course, the containers 1 of the present invention are not in any way limited to yoghurt but can be intended to contain all sorts of liquid, solid, semi-liquid or flowable edible products.

Referring to FIGS. 1-3 and 7-8, the container 1 may be provided with a generally planar annular flange 7 integral with the body 2 and connected to the top 5 of the body 2. The flange 7 or similar upper end comprises a lower face 7 a, an upper face 7 b, an inner edge 7 c defining an upper opening of the container 1, here a generally circular opening 6. The flange 7 may also comprise outer straight side edges 8 a, 8 b, 8 c, 8 d and rounded corners. It can be seen in FIGS. 7-8 that the outer straight side edges 8 a, 8 b, 8 c, 8 d comprise two parallel outer straight side edges 8 a, 8 c and at least one outer straight side edge 8 b, 8 d perpendicular to the two parallel outer straight side edges 8 a, 8 c. Such configuration of the flange 7 may be obtained for containers 1 of a food pack 10. A food pack 10 that comprises four individual containers 1 is illustrated in FIG. 9. Of course the number of containers 1 may vary and a number of 2, 6, 8, 10 or 12 containers 1 may be provided, in a non-limitative example. The containers 1 are arranged in at least one row, and preferably at least in two rows R1, R2 when the pack 10 comprises four or more containers 1. Of course this configuration of the flange 7 or similar shape with rounded corners may be used for an individual container 1 without any connection to adjacent containers.

It can be seen in FIGS. 1-3 that the side wall 4 is provided with an inner shoulder 11 that defines a slope and used for enlarging the width of the upper portion 4 a. The inner shoulder 11 may be rounded to define a continuous convex curvature suitable for movement of a spoon or similar utensil along the side wall 4 in the interior volume V. More generally, the inner shoulder 11 extends from the top of the lower portion 4 b with a vertical component so that it extends not parallel with respect to the plane defined by the bottom 2 a. Surprisingly, it has been found that use of a rounded inner shoulder 11 (that defines a transition between two straight sections or between a straight section and a curved section) does not reduce the overall mechanical properties of the container 1.

Referring to FIGS. 1, 3 and 4A-4B, the barrier layer B1 is obtained using a first flexible closure lid 15, sealed on a first annular surface 16 a that is formed on an interior face 16 of the side wall 4. It can be seen that the first lid 15 may be thin as a membrane seal. The inner shoulder 11 at least partly defines the first annular surface 16 a. The inner shoulder 11 extends at a distance from the bottom 2 a and is spaced from the top 5 of the hollow body 2. When the first flexible closure lid 15 is in annular contact with the inner shoulder 11 onto the first annular surface 16 a, the interior volume V is partitioned into two compartments C1, C2. A solid content, preferably a solid food or a solid object (solid content or at least one article or item), for instance a scooping utensil 18, may be located in the upper compartment C2 above the first flexible closure lid 15. The upper compartment C2 is laterally delimited by the upper portion 4 a that extends from the inner shoulder 11 to the inner edge 7 c. The scooping utensil 18 may be a foldable or collapsible utensil such as a spoon, a straw-like tube, a fork or any similar article. More than one piece of cutlery may be positioned in the upper compartment C2. Other non-limiting examples of solid content are optionally telescopic and/or folded straws, little gifts for promotion, coupons, solid food such as cereals, almonds, nuts, peanuts or the like.

As shown in FIGS. 3, 4A-4B and 5, the first flexible closure lid 15 comprises:

-   a central covering portion 15 a that defines an upper limit of the     lower compartment C1; and -   an annular outer portion 15 b provided with an annular rim 15 c and     which extends upwardly from the central covering portion 15 a to the     annular rim 15 c.     The continuous annular contact with the inner shoulder 11, and more     particularly the contact with the surface 16 a, is here performed by     the annular outer portion 15 b only. Accordingly, effort from the     user to remove the first flexible closure lid 15 may be reduced as     only the annular outer portion 15 b adheres to the interior face 16     of the side wall 4.

As shown in FIGS. 4A, 5 and 7, the annular outer portion 15 b may be folded with respect to the central portion 15 a. The folding line 15 d may be continuous (without any angle). Above the food composition 60, the central portion 15 a may substantially extend in a single plane P that is perpendicular to the longitudinal axis X.

The first flexible closure lid 15 may also be provided with a flap, preferably a pull tab 19, adapted for removing the first flexible closure lid 15 from the first annular surface 16 a. With respect to the annular rim 15 c, it can be seen that the pull tab 19 or similar flap preferably protrudes radially inwards in a folded state as shown in FIG. 3. Alternatively, the pull tab 9 or similar flap may protrude outwards. More generally, a free end 19 a of the pull tab 19 extends at a distance from the inner shoulder 11 to make tearing off of the first flexible lid closure 15 easier.

The upper portion 4 a of the side wall 4 is here connected to the lower portion 4 b via the inner shoulder 11 which is rounded to define a curved connection profile CCP between the lower portion 4 and the upper portion 4 b. Additionally, the side wall 4 may be connected to the bottom 2 a using a curved connection profile with a reverse curvature as compared to the curvature defined by the inner shoulder 11. Keeping a relatively large radius of curvature near the bottom 2 a is here advantageous to maintain a relatively large bottom 2 a. The curved connection profile CCP at the junction between the upper and lower portions 4 a, 4 b is well adapted for forming a stack S of several bodies 2, as shown in FIG. 6.

The lower portion 4 b may have a cylindrical, squared (with rounded corners) or oval section. The junction between the lower portion 4 b and the inner shoulder 11 is defined by a continuous peripheral intersection line (not shown) that is typically included in the plane P. In order to reduce the amount of plastic material, the radial shift or space 28 between this peripheral intersection line and the inner edge 7 c (i.e. radial space 28 measured according to a direction parallel to the plane P as shown in FIG. 6) may be inferior to the minimal radial extension 70 of the flange 7.

Referring to FIGS. 2 and 5-6, the inner shoulder 11 has here a constant height h3, which may be superior or equal to 2 mm. The height h2 of the upper compartment C2 is typically superior to the height h3 and for instance in the range 4-25 mm, preferably 6-15 mm. The ratio h2/H may be inferior to 1/3 and typically in the range 0.05-0.25.

Referring to FIG. 5, the side wall 4 may be optionally provided with more than one radius of curvature r1, r2 above the lower portion 4 b and below the top 5 of the hollow body 2. The first radius of curvature r1 defined by the inner shoulder 11 close to the lower portion 4 b is preferably superior to the second radius of curvature r2 defined close to the top 5 of the body 2. The annular rim 15 c of the first flexible lid closure 15 may extend at the level or slightly above the area provided with the second radius of curvature r2. With a raised position of the annular rim 15 c so as to contact the upper portion 4 a of the side wall 4 (which is shifted radially outwards with respect to the lower portion 4 b that surrounds the food composition 60), a suitable position is obtained for the fingers used to remove the first closure lid 15, whereby any finger contact against the lower portion 4 b is prevented. With such configuration, there is no requirement to provide an especially reinforced pull element in the first flexible lid closure 15 and the removal is easily performed with a single operation.

The barrier layer B2 is obtained using a second flexible closure lid 20 that is adheres around the upper opening 6 to the upper face 7 b of the flange 7 or any similar annular face at the top of the container 1. The second flexible closure lid 20 may cover entirely the upper face 7 b of the flange 7. Referring to the FIGS. 3, 4A-4B and 5, the upper face 7 b comprises a generally planar second annular surface 17 which is in a continuous contact with the second flexible closure lid 20 when the container 1 is provided with the sealing system 3. An air tight sealing may be obtained for the two respective contacts onto the first (non-planar) annular surface 16 a and onto the second (planar) second annular surface 17. When the second flexible closure lid 20 is in its sealing position, the solid content in the upper compartment C2 is not available and cannot be removed without visible degradation of the container 1.

As shown in FIGS. 1 and 5, the two closure lids 15, 20 are each tensioned and the central cover portion 15 a may extend parallel to the second flexible closure lid 20 in the interior volume V.

Referring to FIGS. 7-8, when the container 1 is provided with a flange 7 having one or two specific protruding rounded corners 21 or similar corners of increased size, it is understood, that the cut of the second flexible closure lid 20 is similar, in order to increase the overlapping area with the second flexible closure lid 20. As a result, tearing off of the second flexible closure lid 20 is facilitated. In order to save plastic material, it may be advantageous to provide a flange 7 with a single protruding rounded corner 21 (i.e. a single gripping portion) and with three continuously rounded corners 22 a, 22 b, 22 c (preferably each defining circular outer segments).

The first and second annular surfaces 16 a, 17 obtained by use of the first and second flexible closure lids 15, 20 may be circular in a preferred embodiment as illustrated in FIGS. 3 and 7 in particular. In such a case the opening 6 is circular. More generally, the shape of the first and second annular surfaces 16 a, 17 may be similar to the shape of the opening 6.

Referring to FIG. 5, it can be seen that the annular rim 15 c of the first flexible closure lid 15 is axially spaced from the top 5 of the hollow body 2 and does not extend beyond the plane defined by the second flexible closure lid 20. Advantageously with the location of the upper compartment C2 at the opposite from the bottom 2 a, when the user wishes to retrieve the solid content only (and not the food composition in the lower compartment C1), the second flexible closure lid 20 may be selectively removed.

The sealing system 3 of the container 1 is provided with an inner layer and an outer layer of thin film material (film membrane), respectively defining the first flexible closure lid 15 and the second first flexible closure lid 20. An appropriate cut is performed to define an outer shape of the first and flexible closure lids 15, 20. The first flexible closure lid 15 may have an annular rim which is of a circular shape as the opening 6, while the second flexible closure lid 20 may have an outer edge which has the same shape Preferably, the first and second flexible closure lids 15, 20 are each a one-piece foil of a film material suitable for food contact. The film material may be a bendable sheet plastic or a pliable sheet comprising a composite material and/or aluminium. Preferably, the film material has low water permeability, is approved for food contact and is not flammable.

The foil may be obtained using a flexible multilayer sheet with a top face made of plastic so that this upper face may be marked with information, for instance by ink printing. This is advantageous for individualizing the container 1 (for instance when printing a bar-code onto the upper face of the second closure lid 20 and a coded 2D-pictogramm onto the upper face of the first closure lid 15).

The closure operation may be performed with each of the first and second flexible closure lids 15, 20 by using a fixing material (layer of adhesive) deposited respectively on the first and second annular surfaces 16 a, 17 or deposited on the foil and/or using heat sealing.

The hollow body 2 is here a thermoplastic body obtained from a plastic sheet Sh, preferably a polystyrene sheet (or using similar stretchable material that can be rolled on a reel). In a preferred embodiment, the weight of the thermoplastic body may be less than 30 g, for instance between 15 and 21 g for containing an amount of at least 50 g, preferably at least 100 g, of food composition.

In a preferred embodiment, the hollow body 2 has a flanged cup-like shape and is stretched from a plastic sheet Sh, preferably with a stretching ratio comprised between 2 and 7, preferably between 2.5 and 5. The range 2.5-3.5 may be used for maintaining a high strength in the upper portion 4 a that is not necessarily covered by a decorative strip St. The flange 7 has a constant thickness e, which is higher than the thickness of the side wall 4 at the inner shoulder 11 and preferably higher than the thickness of the lower portion 4 b.

In a particular embodiment, at least one of the second flexible closure lid 20 and the upper portion 4 a comprises a transparent material or a semi-transparent material so that the upper compartment C2 can be viewed before removal of the second flexible closure lid 20. Optionally, the hollow body 2 may be made of a material that is completely transparent or at least transparent in the side wall 4.

Optionally, the body 2 can be made of thermoplastic material with at least one additional layer. Use of a decorative strip St is useful to reinforce the lower portion 4 b of the side wall 4 where the thickness is highly reduced due to the stretching operation for forming the body cavity. The decorative strips St are generally cut out from a film material, such as paper or plastic film, which is printed and stored in the form of a roll, before the strips are cut out.

The covering of the tubular side wall 4 is preferably performed at least around onto an outer annular surface of the lower portion 4 b. The outer surface of the lower portion 4 b is adapted to be covered by any cylindrical or tubular decorative strip St, sticker or banderol (such outer surface preferably having no rim or sharp relief).

The decorative strip St may be a conventional decorative strip having a maximum height equal or superior to the height h1 of the lower portion 4 b. The body cavities may also be provided with a rectilinear upper edge E1 adjacent to the connection profile defined by the inner shoulder 11. No sharp relief is formed near the decorative strip St so as to facilitate the fixing of the thin film material of the decorative strip St.

Fixing of the strip St is performed in a known manner. For instance, the fixing of the strip St is performed after thermoforming the hollow bodies 2 in molds (not shown). Optionally, a preliminary step of cutting out the longitudinal edges from a continuous band is provided. Then, after a step of delivering the bandlets thus obtained to the mold, a step of cutting out the ends of the strips St is carried out in the vicinity of the molds. The strips St may be positioned against the lateral wall of said molds. Such step of positioning the strip is not impaired when using the connection profile of curvature CCP because no sharp protrusion is formed in the lateral wall of the molds.

Referring to FIGS. 1, 3 and 9, the containers 1 may be produced according to a process with a step S1 of forming the hollow body 2, followed by a step S2 of filling with the food composition 60, immediately followed by a step S3 of closing the lower compartment C1 by means of the first closure lid 15. The second closure lid 12 is then attached (step S5) after positioning the solid content (or any kind of additional content) in the upper compartment C2 (step S4). The optional Strip St may be deposited in the mold immediately before the step S1. The solid content (solid food or object), here a scooping utensil 18, may be introduced through the upper opening 6 into the upper compartment C2 (above the flexible closure lid 15), using an air conveyor or a vibrating supply unit.

According to a first embodiment, the thermoformed hollow bodies may be grouped after the step of forming S1 in a stack S as shown in FIG. 6 and the stack S is supplied to a machine that comprises a device for pouring the food composition in the lower compartment C1 and a sealing head. In operation, the film membrane or similar foil is moved into position (adjacent to the sealing head) by rollers of a conveyor. The sealing head is urged downward into an individual body 2 (and above the food composition 60) to seal the film from the film membrane to the inner shoulder 11 of the hollow body 2 which is maintained in a same operating position. The shape of the sealing head is typically adapted to define a first flexible closure lid 15 that is recessed. Indeed, the first flexible closure lid has a 3D shape due to the upwardly extension of the annular outer portion 15 b, preferably with a folding line 15 d between the portions 15 a-15 b. The cutting operation, the pressing operation and the sealing operation may be performed in the step S3 by the sealing head in a conventional manner (for instance, U.S. Pat. No. 4,625,498 shows steps that may be used to apply membrane seals to containers).

The cutting of the membrane film to obtain the first closure lid 15 may be performed just before or during the sealing operation, whereby the sealing head mat be rapidly forced downward thereby preventing the first closure lid 15 from curling back into its original shape. The second flexible closure lid 20 may be applied using a different sealing head of the machine. The cutting operation, the pressing operation and the sealing operation may be performed in the step S5 by such sealing head in a conventional manner to obtain the planar configuration of the second flexible closure lid 20.

According to this first embodiment, the steps S2, S3, S4 and S5 may be performed starting from individual bodies 2. As shown in FIG. 9. The film membranes FM are provided from a feeding reel 25 and supplied at respective steps 150 and 200. The cutting step 152 to delimit the outer edge of the first flexible closure lid 15 may optionally be performed before the step S3 of closing the lower compartment C1. After the cutting step 202 to delimit the outer edge of the second flexible closure lid 20 and after the step S3, the upper compartment C2 may be closed in a conventional manner during the step S5 and individual containers 1 may be grouped in a tray T.

According to a second embodiment, the steps S1-S5 of the manufacturing method are carried out by means of a FFS production machine (Form, Fill and Seal). It is advantageous to implement the thermoforming process in machines using the high rate technology FFS to efficiently produce food packs 10.

In such case, the plastic sheet Sh supplied from the reel 26 is not cut after the step S1. The hollow bodies 2 are formed from a sheet Sh of plastics material clamped between a mold having one or more forming impressions against a backing mold in which one or more forming dies are displaced, filled and closed. The plastic sheet Sh with the body cavities is filled with the food composition 60 at the step S2. In the FFS machine or outside the FFS machine (for instance in an auxiliary machine), two additional modules are added for respectively performing the steps S3 and S4. The first module may comprise a plurality of sealing heads and it is understood that the cutting operation, the pressing operation and the sealing operation for adhering the annular outer portion 15 b of the first closure lid 15 to the inner shoulder 11 are typically performed in a conventional manner in the step S3. The second module simply comprises an air conveyor, a vibrating supply unit or any similar unit for distribution of the solid content, here a scooping utensil 18, in the upper compartment C2. The first and second modules are provided to operate after the filling performed by a filling unit at the step S2. The means used to apply the second flexible closure lid 20 may operate as in a FFS machine for producing conventional flanged cup-like containers.

It can be seen in FIG. 9 a top view of a food pack 10 of several containers 1 that can be produced after a final cutting step or after the closing of the upper compartment C2.

As shown in FIG. 9, when arranged in a tray T, each pack 10 of the containers 1 is arranged inside the interior volume defined by the tray T. It can be seen that the containers 1 of a food pack 10 are separably joined to each other at a junction J of two flange portions of two distinct containers 1 of the pack 10.

The containers 1 are intended to be filled with any liquid or semi-liquid dairy product or similar food, preferably a yoghurt composition. The containers 1 can be used for 50-500 g capacity, preferably 75-200 g or 80-400 g capacity. Of course, the containers 1 of the present invention are not in any way limited to yoghurt but can be intended to contain all sorts of liquid, semi-liquid or flowable edible products.

The upper compartment C2 has been described to contain a solid content. When adding a scooping utensil 18, it can be optionally made from edible material that is relatively rigid and not structurally degraded by contact with the food composition 60. Other embodiments are also provided for the content of the upper compartment C2. For instance, a flexible content or liquid content may be introduced between the first and second flexible closure lid 15, 20.

The present invention has been described in connection with the preferred embodiments. These embodiments, however, are merely for example and the invention is not restricted thereto. For instance, the flanges 7 shown in FIGS. 3, 7-9 can be replaced by any flanges having a shape adapted for removal of the second closure lid 20. The shape of the opening 6 and the flange 7 are particularly user-friendly while the arrangement of the body 2 remains very compact when containing a food composition 60.

Although the Figures show a body 2 having a circular cross-section and a circular opening 6, other shapes may be used, for instance a rectangular shape with rounded corners or an oval shape.

It will be understood by those skilled in the art that other variations and modifications can easily be made within the scope of the invention as defined by the appended claims, thus it is only intended that the present invention be limited by the following claims.

Any reference sign in the following claims should not be construed as limiting the claim. It will be obvious that the use of the verb “to comprise” and its conjugations does not exclude the presence of any other elements besides those defined in any claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. 

1. A two compartment container for a food composition, comprising: a body comprising a bottom and a side wall extending along a longitudinal axis from the bottom to a top, the body being a thermoplastic hollow body; a first annular surface formed on an interior face of the side wall, the first annular surface extending between the bottom and the top of the hollow body; a generally planar second annular surface surrounding an upper opening of the container; a first flexible closure lid, sealed on the first annular surface so that a lower compartment is defined between the bottom and the first flexible closure lid; and a second flexible closure lid, sealed on the second annular surface so that an upper compartment is defined at the opposite from the bottom between the first flexible closure lid and the second flexible closure lid; wherein the side wall is provided with an inner shoulder that defines a slope and wherein the first flexible closure lid comprises: a central covering portion that defines an upper limit of the lower compartment; an annular rim; and an annular outer portion that comprises the annular rim and extends upwardly from the central covering portion to the annular rim, said annular outer portion being in continuous annular contact with the inner shoulder.
 2. The container of claim 1, wherein the side wall comprises an upper portion and a lower portion the upper portion being connected to the lower portion via the inner shoulder which is rounded to define a curved connection profile between the lower portion and the upper portion.
 3. The container of claim 2, wherein the side wall is annularly covered by a decorative strip.
 4. The container of claim 2, wherein the side wall is provided with more than one radius of curvature above the lower portion and below the top of the body.
 5. The container according to claim 1, wherein the inner shoulder has a constant height which is superior or equal to 2 mm.
 6. The container according to claim 1, wherein the first flexible closure lid is a one-piece foil of a film material and the annular outer portion is folded with respect to the central portion, and wherein the second flexible closure lid is a one-piece foil.
 7. The container according to claim 1, wherein the annular rim of the first flexible closure lid is axially spaced from the top of the body.
 8. The container according to claim 1, wherein the first flexible closure lid comprises a flap adapted for removing the first flexible closure lid from the first annular surface, the flap protruding radially outwards and/or inwards in a folded state, the flap comprising a free end that extends at a distance from the inner shoulder.
 9. The container according to claim 1, comprising a generally planar annular flange integral with the body and connected to the top of the body, the flange defining the second annular surface and comprising an inner edge that defines the upper opening of the container.
 10. The container according to claim 9, wherein the flange has a constant thickness which is higher than the thickness of the side wall at the inner shoulder.
 11. The container according to claim 1, wherein the body has a flanged cup-like shape and is stretched from a plastic sheet.
 12. The container according to claim 1, wherein the lower compartment is filled with a food composition and the upper compartment contains an article in a solid state.
 13. The container according to claim 1, wherein at least one of the second flexible closure lid and an upper portion of the side wall comprises a transparent material or a semi-transparent material so that the upper compartment can be viewed before removal of the second flexible closure lid. 14.-15. (canceled)
 16. A food pack comprising a plurality of containers for a food composition, wherein each of the containers is a two compartment container and comprises: a body comprising a bottom and a side wall extending along a longitudinal axis from the bottom to a top, the body being a thermoplastic hollow body; a first annular surface formed on an interior face of the side wall, the first annular surface extending between the bottom and the top of the body; a generally planar second annular surface surrounding an upper opening of the container; a first flexible closure lid, sealed on the first annular surface so that a lower compartment is defined between the bottom and the first flexible closure lid; and a second flexible closure lid, sealed on the second annular surface so that an upper compartment is defined at the opposite from the bottom between the first flexible closure lid and the second flexible closure lid; wherein the side wall is provided with an inner shoulder that defines a slope and wherein the first flexible closure lid comprises: a central covering portion that defines an upper limit of the lower compartment; an annular rim; and an annular outer portion that comprises the annular rim and extends upwardly from the central covering portion to the annular rim, said annular outer portion being in continuous annular contact with the inner shoulder; and wherein each of the containers comprises a generally planar annular flange integral with the body and defining the second annular surface, and said containers are arranged in at least one row and separably joined to each other at a junction of two flange portions of two distinct containers of the pack.
 17. A method of making a two-compartment container, using a container having a bottom and an upper opening and a cavity defined by a thermoplastic hollow body, the method comprising: providing the thermoplastic hollow body with a side wall extending along a longitudinal axis from the bottom to a top, the side wall having on an interior face thereof a first annular surface and an inner shoulder that defines a slope, and providing the thermoplastic hollow body with a generally planar second annular surface surrounding the upper opening; filling the cavity defined by the thermoplastic hollow body with a food composition entirely below the inner shoulder; shaping a first flexible closure lid according to a 3D shape when attaching an annular outer portion of the first flexible closure lid to the inner shoulder, in order to seal a lower compartment of the container, a central covering portion of the first flexible closure lid defining an upper limit of the lower compartment, the annular outer portion extending upwardly from the central covering portion to an annular rim and continuously contacting the inner shoulder; positioning through the upper opening a solid content into an upper compartment of the container above the first flexible closure lid; closing the upper opening and sealing the upper compartment by attaching a second flexible closure lid to an upper end of the thermoplastic hollow body, the second flexible closure lid being sealed on the second annular surface and defining an upper limit of the upper compartment. 